Carpet products and methods of making same

ABSTRACT

A carpet product including a primary backing layer and a plurality of yarn tufts. The plurality of yarn tufts are tufted in and extend upwardly from a top surface of the primary backing layer to form a tufted carpet product. The carpet product has an inner portion and a peripheral portion surrounding at least a portion of the inner portion and extending along at least one of the edges of the primary backing layer. The plurality of yarn tufts include a plurality of peripheral yarn tufts positioned within the peripheral portion of the tufted carpet product. A portion of the peripheral yarn tufts are anchored to other peripheral yarn tufts. At least a portion of each anchored peripheral yarn tuft is entangled with one or more of the other peripheral yarn tufts.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.15/428,606, filed Feb. 9, 2017, which claims priority to and the benefitof U.S. Provisional Patent Application Ser. No. 62/292,941, filed Feb.9, 2016, each of which is hereby incorporated by reference herein in itsentirety.

FIELD

The disclosed invention relates to carpet products and methods of usingsuch carpet products. In exemplary aspects, the disclosed inventionrelates to carpet products having anchored peripheral yarn tufts thatare entangled with one or more vertical peripheral yarn tufts.

BACKGROUND

When an initial tile cutting manufacturing process is complete, the baseedge is straight and a free of stray tufted face fibers with all facefibers standing in an erect position or substantially perpendicular tothe backing and floor. Above the base, the tufted carpet fiber can beeasily moved and pressed laterally into the area where there is nobacking under the fibers, and these fibers can be trapped under adjacenttiles when installed with other tiles with the same or similar tuftingconstruction.

Conventional carpet manufacturing methods and systems have historicallyproduced carpet products with unsecured edge carpet fibers along theperimeter of the carpet products, as shown in FIGS. 1A and 1B. Such edgecarpet fibers have historically been easily moved and pressed laterallyinto an area where there is no backing underneath the fibers,particularly during shipping and handling of the carpet products.Movement of these unsecured edge carpet fibers in an undesirableposition, often parallel to the backing and extending away from thecenter of the carpet product, can cause the edge fibers to becometrapped underneath adjacent carpet products during installation withother carpet products having the same or similar tufting construction.

To reduce the entrapment of these edge carpet fibers underneath adjacentcarpets, carpet products conventionally have been beveled and/or shearedto remove the fibers from the edges. However, these methods do notprevent movement of the carpet fibers during the period of shipment ortransport of the carpet product to the site of installation. Thus, suchmethods require the carpet installer to have the proper equipment readyfor beveling and/or shearing and to invest considerable time and effortinto cutting the edge carpet fibers on-site, which ultimately reducesefficiency and delays the installation process. Additionally, as pileheight increases, the probability of trapping fiber on the edgesincreases. The instance of trapped fibers generally more severe when thepile height of the tufted fiber is greater than ⅜″ and is a cut pilecarpet. Trapped fiber under the edge can prevent tiles from completelyfitting together at the seam, which can cause out of square conditions,puckers and bumps at the seams in the finished carpet afterinstallation.

Thus, there is a need for carpet products having secured edge fibersalong the perimeter edges of the carpet product. There is a further needfor methods and systems of securing the edge carpet fibers in an uprightposition to reduce the likelihood of the fibers being pressed into anundesirable position during the period of shipment and installation ofthe carpet product, thereby improving the overall quality of theinstallation process.

SUMMARY

Described herein, in various aspects, is a carpet product including aprimary backing layer and a plurality of yarn tufts. The primary backinglayer can have a top surface and a plurality of edges. The plurality ofyarn tufts can be tufted in and extend upwardly from the top surface ofthe primary backing layer to form a tufted carpet product. The tuftedcarpet product can have an inner portion and a peripheral portionsurrounding at least a portion of the inner portion and extend along atleast one of the edges of the primary backing layer. The plurality ofyarn tufts can include a plurality of peripheral yarn tufts positionedwithin the peripheral portion of the tufted carpet product. Theplurality of peripheral yarn tufts can include a first plurality ofperipheral yarn tufts and a second plurality of peripheral yarn tufts.The first plurality of peripheral yarn tufts are anchored to the secondplurality of peripheral yarn tufts. At least a portion of each anchoredperipheral yarn can be entangled with one or more of the peripheral yarntufts of the second plurality of peripheral yarn tufts.

In other aspects, described herein is a carpet product including aprimary backing layer and a plurality of yarn tufts. The primary backinglayer can have a top surface and a plurality of edges. The plurality ofyarn tufts can be tufted in and extend upwardly from the top surface ofthe primary backing layer to form a tufted carpet product. The tuftedcarpet product can have an inner portion and a peripheral portionsurrounding at least a portion of the inner portion and extend along atleast one of the edges of the primary backing layer. The plurality ofyarn tufts can include a plurality of peripheral yarn tufts positionedwithin the peripheral portion of the tufted carpet product. Theplurality of peripheral yarn tufts can include a first plurality ofperipheral yarn tufts and a second plurality of peripheral yarn tufts.The yarn tufts of the first plurality of peripheral yarn tufts areanchored to one or more yarn tufts of the second plurality of peripheralyarn tufts. At least a portion of each anchored peripheral yarn can beentangled with one or more of the peripheral yarn tufts of the secondplurality of peripheral yarn tufts. The entanglement of peripheral yarntufts can ensure that no peripheral yarn extends radially beyond areference plane that is positioned at a selected angle relative to avertical plane that is substantially perpendicular or perpendicular tothe primary backing layer. Optionally, the selected angle can be lessthan about 40 degrees.

Disclosed herein, in further aspects, is a method that includesdisplacing a first plurality of peripheral yarn tufts of a tufted carpetproduct in an inward direction to entangle a second plurality ofperipheral yarn tufts of the tufted carpet product. Each of theperipheral yarn tufts can be tufted in and extend upwardly from a topsurface of a primary backing layer of the tufted carpet product. Theentanglement of the yarn tufts of the first plurality of peripheral yarntufts with the yarn tufts of the second plurality of peripheral yarntufts anchors the first plurality of peripheral yarn tufts in a desiredorientation relative to the primary backing layer.

DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B display exemplary conventional carpet products. FIG. 1Adisplays a conventional carpet product having unsecured edge carpetfibers. FIG. 1B displays a conventional carpet product having trappedfibers at the tile seam.

FIG. 2 displays an exemplary carpet product having entangled carpetfibers as described herein.

FIG. 3 displays an exemplary carpet product having entangled carpetfibers as described herein. As shown, the carpet product includes addedfibers to promote entanglement among the carpet fibers.

FIGS. 4A and 4B depict plan views of exemplary needles as describedherein, namely, a single reduction needle (FIG. 4A) and a doublereduction needle (FIG. 4B).

FIG. 5 is an isometric view of an exemplary carpet product and anexemplary assembly for creating entanglement between carpet fibers asdescribed herein. As shown, the assembly can include a plate and needlesthat are received within openings of the plate.

FIG. 6A is a plan view of an exemplary carpet product that isneedle-punched on all four sides as described herein and situated withina frame having a known area, referred to herein as A_(frame1). Thecarpet product of FIG. 6A has a backing with a known area, referred toherein as A_(tile). FIG. 6B is a plan view of a conventional carpetproduct positioned within the frame. As shown, the conventional carpetproduct has unsecured edges that extend outwardly from the carpetproduct (and outside of A_(tile)). As further described herein, imagingsystems can be used to calculate the total area of the fibers of carpetproducts (e.g., needle-punched and conventional carpet products) thatextend outside of known A_(tile). These imaging systems can also be usedto compare the area of the fibers of the conventional carpet productthat extend outside A_(tile) to the area of the fibers of theneedle-punched carpet product that extend outside A_(tile). Thiscomparison can provide an indication of the ability of the methodsdisclosed herein to secure peripheral carpet fibers in a desiredorientation relative to the edge of the carpet product.

FIG. 7A is a side perspective view of an exemplary carpet product havingentangled peripheral yarn tufts as described herein. As shown, in anideal carpet product, the peripheral yarn tufts do not extend beyond areference plane that is coincident with or positioned at an acute anglerelative to a vertical plane. FIG. 7B is a perspective view of aconventional carpet product with unsecured edge fibers as describedherein. As shown, the peripheral yarn tufts of the conventional carpetproduct extend well beyond the reference plane shown in FIG. 7A.

FIG. 8A is an isolated perspective view of a peripheral edge of a carpetproduct having a plurality of peripheral yarn tufts. As shown, each ofthe peripheral yarn tufts is tufted in and extends upwardly from the topsurface of a primary backing layer of the tufted carpet product. Asfurther described herein, the peripheral yarn tufts can include a firstplurality of yarn tufts and a second plurality of yarn tufts. FIG. 8B isan isolated perspective view of the peripheral edge of the carpetproduct of FIG. 8A, showing the displacement of yarn from among thefirst plurality of yarn tufts to orient portions of the yarnsubstantially parallel or parallel to the primary backing layer andentangle the yarn with yarn tufts of the second plurality of yarn tufts.FIG. 8C depicts the carpet product of FIGS. 8A-8B following entanglementbetween the first plurality of yarn tufts and the second plurality ofyarn tufts.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout. It is tobe understood that this invention is not limited to the particularmethodology and protocols described, as such may vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to limit thescope of the present invention.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which theinvention pertains having the benefit of the teachings presented in theforegoing description and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

As used herein the singular forms “a”, “an”, and “the” include pluralreferents unless the context clearly dictates otherwise. For example,use of the term “a fiber” can refer to one or more of such fibers.

All technical and scientific terms used herein have the same meaning ascommonly understood to one of ordinary skill in the art to which thisinvention belongs unless clearly indicated otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list.

The following description supplies specific details in order to providea thorough understanding. Nevertheless, the skilled artisan wouldunderstand that the apparatus and associated methods of using theapparatus can be implemented and used without employing these specificdetails. Indeed, the apparatus and associated methods can be placed intopractice by modifying the illustrated apparatus and associated methodsand can be used in conjunction with any other apparatus and techniquesconventionally used in the industry.

Disclosed herein, in various aspects and with reference to FIGS. 1-8C,are carpet products 10 and methods of making such carpet products. Inexemplary aspects, the carpet product 10 can be a broadloom carpet. Inother exemplary aspects, the carpet product can be a carpet tile.However, it is contemplated that the carpet product 10 can comprise anyconventional carpet product, including, for example and withoutlimitation, bulk continuous fiber carpet products, spun carpet products,turf products, rugs, patches, and the like. As further described herein,the carpet products can have edge fibers that are secured to preventand/or limit fibers extending beyond an edge of the carpet product.

In one aspect, as shown in FIGS. 2 and 3 , the carpet product 10 cancomprise a primary backing layer 12 having a top surface 14 and aplurality of edges 16. In another aspect and with reference to FIGS. 2,3 and 5 , the carpet product 10 can comprise a plurality of yarn tufts18 tufted in and extending upwardly from the top surface 14 of theprimary backing layer 12 to form a tufted carpet product 10. In thisaspect, the tufted carpet product 10 can have an inner portion 22 and aperipheral portion 24 surrounding at least a portion of the innerportion and extending along at least one of the edges 16 of the primarybacking layer 12. As used herein, the term “yarn tuft” refers to anyyarn or fiber structure that extends upwardly from a primary backinglayer. In exemplary aspects, a “yarn tuft” as disclosed herein can beformed by a conventional tufting process and can cooperate with otheryarn tufts to define a face of a carpet product. Each yarn tuft can haveany suitable tuft profile, including, for example and withoutlimitation, cut yarn stitches or loop yarn stitches. It is contemplatedthat the tufted carpet products 10 disclosed herein can comprise yarntufts having varying tuft profiles, including, for example, acombination of cut yarn stitches and loop yarn stitches. In exemplaryaspects, the plurality of yarn tufts 18 can comprise a plurality ofperipheral yarn tufts 26 positioned within the peripheral portion 24 ofthe tufted carpet product 10. In these aspects, the plurality ofperipheral yarn tufts 26 can comprise a first plurality of peripheralyarn tufts 30 and a second plurality of peripheral yarn tufts 28.Optionally, the first plurality of peripheral yarn tufts 30 can bepositioned proximate at least one edge of the carpet product 10. Infurther aspects, the first plurality of peripheral yarn tufts 30 can beanchored to the second plurality of peripheral yarn tufts 28.

As further disclosed herein and shown in FIGS. 8A-8C, each anchoredperipheral yarn tuft of the first plurality of peripheral yarn tufts 30can be secured to other yarn tufts of the carpet product 10 to preventor limit extension of portions of peripheral yarn tufts beyond an edgeof the carpet product. It is contemplated that a peripheral yarn tuft ofthe first plurality of peripheral yarn tufts 30 can be entangled withand coupled to at least one yarn tuft of the second plurality ofperipheral yarn tufts 28 to maintain the peripheral yarn tufts of thesecond plurality of peripheral yarn tufts 28 in a desired position. Forexample, entanglement between the first plurality of peripheral yarntufts 30 and the second plurality of peripheral yarn tufts 28 can ensurethat the second plurality of peripheral yarn tufts are maintained in asubstantially vertical position relative to the primary backing layer12. In these aspects, the entanglement of the first and second pluralityof peripheral yarn tufts 30, 28 can ensure that no peripheral yarn tuftof the first plurality of peripheral yarn tufts extends radially beyonda reference plane 42 that is positioned at a selected angle 44 relativeto a vertical plane 46 that is substantially perpendicular orperpendicular to the primary backing layer 12. In exemplary aspects, itis contemplated that the second plurality of peripheral yarn tufts 28can be considered “substantially vertical” when the yarn tufts are:parallel or substantially parallel to the vertical plane 46 (i.e.,perpendicular or substantially perpendicular to the primary backinglayer 12) or at an angle of 60 degrees to 120 degrees with respect tothe primary backing layer 12 or, optionally, at an angle of 75 degreesto 105 degrees with respect to the primary backing layer or, optionally,at an angle of about 90 degrees with respect to the primary backinglayer. Optionally, upon entanglement between an anchored peripheral yarntuft of the first plurality of peripheral yarn tufts 30 and another yarntuft (optionally, another peripheral yarn tuft), the non-entangledfibers of the anchored peripheral yarn tuft 30 can be retained in asubstantially vertical position. In this optional aspect, it iscontemplated that the non-entangled fibers of the anchored yarn tufts ofthe first plurality of peripheral yarn tufts 30 can be considered“substantially vertical” when the non-entangled fibers of the yarn tuftsare parallel or substantially parallel to the vertical plane 46 (i.e.,perpendicular or substantially perpendicular to the primary backinglayer 12) or at an angle of 50 degrees to 130 degrees with respect tothe primary backing layer 12 or, optionally, at an angle of 75 degreesto 105 degrees with respect to the primary backing layer or, optionally,at an angle of about 90 degrees with respect to the primary backinglayer.

Each yarn tuft of the plurality of peripheral yarn tufts 26 of thecarpet product 10 can comprise a plurality of filaments 27 that arebunched together to produce the yarn tuft. In exemplary aspects, asshown in FIG. 8C, at least a portion (e.g., at least one filament 27) ofeach anchored peripheral yarn tuft of the first plurality of peripheralyarn tufts 30 can be displaced inwardly (away from an edge of the carpetproduct 10 to engage and become entangled with one or more peripheralyarn tufts of the second plurality of peripheral yarn tufts 28.Optionally, as shown in FIG. 8C, a plurality of filaments 27 of at leastone anchored peripheral yarn tuft of the first plurality of peripheralyarn tufts 30 can engage and become entangled with one or moreperipheral yarn tufts (optionally, one or more adjacent peripheral yarntufts) of the second plurality of peripheral yarn tufts 28. Optionally,in some aspects, it is contemplated that entangled filaments of theanchored peripheral yarn tufts of the first plurality of peripheral yarntufts 30 can be oriented substantially parallel or parallel to theprimary backing layer 12; however, it is contemplated that anyorientation of the entangled filaments can be employed, providedsufficient engagement between the anchored peripheral yarn tuft 30 andthe peripheral yarn tuft of the second plurality of peripheral yarntufts 28 is achieved. In these aspects, it is contemplated that theentangled filaments of an anchored peripheral yarn tuft of the firstplurality of peripheral yarn tufts 30 can be considered “substantiallyparallel” to the primary backing layer 12 when they are parallel to theprimary backing layer or are aligned with an axis that forms an acuteangle less than 30 degrees (optionally, less than 15 degrees) with aplane 13 that coincides with, or is generally aligned with, the primarybacking layer. As used herein, the term “entangle” or “entangled” refersto mechanical engagement between a displaced (e.g., anchored) yarn tuft30 or filament 27 and another yarn tuft or filament that is sufficientto retain the anchored yarn tuft in a desired position (e.g., asubstantially vertical position) relative to the primary backing layer12. In exemplary aspects, at least one filament from an anchored yarntuft of the first plurality of peripheral yarn tufts 30 is inwardlydisplaced until it contacts and becomes engaged and entangled withportions of another yarn tuft, such as within gaps between filaments 27of the yarn tuft that serves as an anchor for the anchored yarn tuft. Asfurther disclosed herein, it is contemplated that entanglement asdescribed herein can prevent portions of the anchored yarn tufts fromextending beyond an edge of the carpet product in an undesired manner.

In exemplary aspects, it is contemplated that at least one (optionally,each) anchored peripheral yarn tuft 30 can become entangled with asingle, corresponding peripheral yarn tuft 28. In other exemplaryaspects, it is contemplated that at least one (optionally, each)anchored peripheral yarn tuft 30 can become entangled with a pluralityof peripheral yarn tufts 28. In still further exemplary aspects, it iscontemplated that at least one (optionally, each) anchored peripheralyarn tuft 30 can become entangled with both a peripheral yarn tuft 28and another anchored peripheral yarn tuft.

Although the entanglement between two adjacent yarn tufts is describedherein as being applied to peripheral yarn tufts near an edge of acarpet product, it is contemplated that such entanglement can also beproduced between adjacent yarn tufts within other portions (e.g., innerportions) of a carpet product to maintain a desired position (e.g., adesired vertical or substantially vertical position) of yarn tuftsrelative to the primary backing layer. It is further contemplated thatthe disclosed entanglement can be used to maintain yarn tufts in desiredangled or non-vertical positions. Although generally described herein asproducing entanglement between peripheral yarn tufts, it is contemplatedthat, in some exemplary aspects, the carpet products disclosed hereincan include peripheral yarn tufts that are inwardly displaced from anedge of a carpet to become entangled with yarn tufts that are

Optionally, in exemplary aspects, the pile height of the tufted yarntufts 18 of the carpet product 10 can vary over the tufted carpet.

Optionally, in further exemplary aspects, the peripheral portion 24 ofthe tufted carpet product 10 can completely surround the inner portion22 of the tufted carpet product. In these aspects, the peripheralportion 24 can extend inwardly from the edges 16 of the primary backinglayer 12 and have a width that is less than about 30% of the operativewidth of the tufted carpet.

In exemplary aspects and with reference to FIGS. 7A and 7B, followingentanglement with the second plurality of peripheral yarn tufts 28, theperipheral yarn tufts of the first plurality of peripheral yarn tufts 30can have a mechanical stand fastness sufficient to prevent radialdisplacement of any peripheral yarn tuft of the first plurality ofperipheral yarn tufts beyond a reference plane 42 that is positioned ata selected angle 44 relative a vertical plane 46 that is substantiallyperpendicular or perpendicular to a plane 13 coinciding with (i.e.,containing) the primary backing layer 12. As shown in FIG. 7A, thevertical plane 46 can coincide with an edge of the carpet product 10.Optionally, in these aspects, the selected angle 44 can be less thanabout 40 degrees. In other aspects, the selected angle 44 can be lessthan about 30 degrees. In other aspects, the selected angle 44 can beless than about 20 degrees. In still other aspects, the selected angle44 can be less than about 10 degrees. In still other aspects, theselected angle 44 can be less than about 5 degrees. In still otheraspects, the selected angle 44 can be about 0 degrees such that thereference plane substantially corresponds to the vertical plane 46. Instill other aspects, the selected angle 44 can be negative (e.g., −5degrees or greater, −10 degrees or greater, −15 degrees or greater, −20degrees or greater, and the like) such that at least a portion of theanchored peripheral yarn tuft of the first plurality of peripheral yarntufts 30 is angled inwardly away from an edge of the carpet product.

In one exemplary aspect, at least a portion (e.g., at least onefilament) of at least one anchored peripheral yarn tuft of the firstplurality of peripheral yarn tufts 30 can be entangled with one or moreyarn tufts within the inner portion 22 of the tufted carpet product 10.In another exemplary aspect, at least a portion (e.g., at least onefilament) of at least one anchored peripheral yarn tuft 30 can beentangled with at least two other yarn tufts of the tufted carpetproduct 10.

In still another exemplary aspect, at least one filament of at least oneanchored peripheral yarn tuft of the first plurality of peripheral yarntufts 30 can have a tip 34 that is displaced inwardly by a selecteddistance when the anchored peripheral yarn tuft is entangled with otheryarn tufts. In this aspect, it is contemplated that the selecteddistance can range from about 0.1 inch to about 1.0 inch.

Methods of Making Carpet Products

In one aspect, as shown in FIGS. 8A-8C, a carpet product 10 as disclosedherein can be produced by displacing a first plurality of peripheralyarn tufts 28 of a tufted carpet product 10 in an inward direction toentangle a second plurality of peripheral yarn tufts 30 of the tuftedcarpet product. In this aspect, each of the peripheral yarn tufts 28, 30can be tufted in and extend upwardly (optionally, substantiallyperpendicularly or perpendicularly) from a top surface 14 of a primarybacking layer 12 of the tufted carpet product 10. As further disclosedherein, at least a portion (e.g., at least one filament) of each yarntuft of the first plurality of peripheral yarn tufts 28 can be orientedinwardly away from an edge of the carpet product 10 to engage and becomeentangled with at least one yarn tuft of the second plurality ofperipheral yarn tufts 30. As further disclosed herein, the firstplurality of yarn tufts 28 and the second plurality of yarn tufts 30 canbe positioned within a peripheral portion 24 of the tufted carpetproduct 10, and the peripheral portion of the tufted carpet product cansurround at least a portion of an inner portion 22 of the tufted carpetproduct. As further disclosed herein, in some aspects, at least aportion (i.e., at least one filament) of at least one yarn tuft of thefirst plurality of yarn tufts (i.e., an anchored peripheral yarn tuft30) can be entangled with one or more yarn tufts within the innerportion 22 of the tufted carpet product 10. Optionally, in theseaspects, at least one yarn tuft of the first plurality of yarn tufts(i.e., an anchored peripheral yarn tuft 30) can be entangled with atleast two other yarn tufts of the tufted carpet product 10.

In exemplary aspects and as shown in FIGS. 4A-5 , the first plurality ofperipheral yarn tufts 28 can be displaced using at least one needle 100that is inserted into the peripheral yarn tufts in the inward direction.In further aspects, the at least one needle 100 can be inserted into theperipheral yarn tufts 26 at a desired time and speed. For example, inthese aspects, each needle 100 can reciprocate at a rate ranging from100 strokes per minute to about 2,000 strokes per minute. Moreparticularly, in some aspects, each needle 100 can reciprocate at a rateranging from 200 strokes per minute to about 1,000 strokes per minute.

In still further aspects, the at least one needle 100 can be insertedthrough at least one opening 104 in a plate 102. In these aspects, theplate 102 can be oriented substantially perpendicular or perpendicularto the primary backing layer 12, and the inward direction can besubstantially parallel or parallel to the primary backing layer.Optionally, it is contemplated that the plate 102 can be substantiallyflush and/or aligned with an edge of the carpet product. In exemplaryaspects, each needle 100 can be inserted within the peripheral yarntufts 26 to a location that is a selected distance (in an inwarddirection) from an edge of the primary backing layer 12 of the tuftedcarpet product 10. Optionally, in these aspects, the selected distancecan range from about 0.1 inch to about 1 inch.

In one exemplary aspect, as further disclosed herein, the at least oneneedle 100 can comprise at least one barbed needle that mechanicallysecures the face filaments to one another on the edge(s) of the carpetproduct in a direction that is substantially perpendicular (optionally,perpendicular) to the tufted direction of the face filaments. In thisaspect, as the needle penetrates the peripheral yarn tufts, somefilaments can become lodged in the barbed section of the needle and canthen be pushed and pulled in the direction of the needle travel untilthe displaced filaments engage filaments of adjacent fiber bundles (yarntufts). The use of needles in this manner can create filament anchors inthe yarn tuft filament bundles of adjacent filament bundles and canphysically connect the filaments as they are sewn into other filamentbundles. In exemplary aspects, as the distal end of each needle isadvanced from the periphery of the carpet product in an inwarddirection, it is contemplated that the needle can create gaps withininner yarn tufts that are capable of receiving filaments or groups offilaments that have been displaced from an anchored yarn tuft toincrease or promote entanglement as further disclosed herein.

It is contemplated that various sizes and constructions of needles canbe used as disclosed herein. Preferably, in one aspect, the needles canbe barbed in the direction of insertion into the edge of the tile. Inthis aspect, the tile can be held in place substantially parallel orparallel to the needling apparatus. The depth and stroke speed can bedetermined by the carpet fiber type and the density of the carpet facefiber. The carpet product can be needled along an edge of the carpetproduct as it passes the reciprocating needle bar. The number of needlesand the count of stokes can be determined by the construction of thecarpet face filaments and the need for the security of the filaments tointerlock.

Optionally, in some aspects, the at least one opening 104 of the plate102 can comprise a plurality of openings 104. In these aspects, theplurality of openings 104 can optionally be staggered relative to atleast one axis. In other aspects, the plurality of openings 104 canoptionally be linear. In exemplary aspects, each opening 104 of theplurality of openings 104 can be spaced from adjacent openings by apredetermined distance ranging from about 1 mm to about 3 cm.

Thus, in exemplary aspects, the carpet products disclosed herein canhave secured edge carpet yarn tufts of a cut pile face on the perimeterof the carpet product. As disclosed herein, in exemplary aspects, theedge carpet yarn tufts can be secured in such a manner by inwardlydisplacing filaments of the edge yarn tufts to create entanglement withfilaments of substantially vertical yarn tufts; however, it iscontemplated that any mechanical or chemical means for bonding orsecuring the edge yarn tufts in a substantially upright orientation canbe employed to reduce the possibility of the edge yarn tufts beingtrapped between adjacent carpet products when installed. Optionally, inexemplary aspects, the mechanical means can be used to push filamentslocated on the perimeter of a carpet product into adjacent tufts of thesame carpet product to create a physical connection of the filaments. Ineven further aspects, the mechanical means can comprise a source ofhigh-pressure air and/or water. In these aspects, the source ofhigh-pressure air and/or water can provide jets of air and/or waterhaving sufficient energy to move filaments from the tufted bundle so asto have stray filaments pushed into adjacent filaments to make fibrousmechanical connections. In other aspects, the mechanical means cancomprise a heated rod and/or a heated shoe. In these aspects, the heatedrod and/or heated shoe can be used to heat fuse the edge yarntufts/filaments. In further aspects, the mechanical means can comprisethreads that can be sewn into the edges to secure the yarntufts/filaments. In even further aspects, the mechanical means cancomprise ultrasonic pins to secure the edge yarn tufts/filaments. Inother aspects, the mechanical means can comprise mechanical combing ofthe edge yarn tufts/filaments. In other aspects, the mechanical meanscan comprise vacuum combing behind the edge yarn tufts/filaments. Infurther aspects, the mechanical means can comprise hot air jets. Inthese aspects, the hot air jets can be used to move and fuse the edgeyarn tufts/filaments. In even further aspects, the mechanical means cancomprise at least one brush or pin, which can be either metallic ornon-metallic. In these aspects, the brush or pin can be used to push theedge filaments into adjacent yarn tufts/filaments. In other aspects, themechanical means can comprise affixed paper tabs. In these aspects, theaffixed paper tabs can be removed once the carpet product (e.g., tile)is installed to provide a physical barrier and keep the filamentsaffixed.

Alternatively, in other exemplary aspects, a chemical means, such as awater borne chemical capable of adhering the edge yarn tufts/filamentstogether, can be applied to improve the vertical nature of the yarntufts/filaments in the same manner as described herein by chemicallyadhering the yarn tufts/filaments on the perimeter. In one aspect, it iscontemplated that the chemical means can comprise starches or othersimilar non-permanent adhesives, such as waxes, that chemically “glue”the edge yarn tufts/filaments of the carpet product together. In thisaspect, it is contemplated that the chemicals can be spray applied orbrush applied to the edge yarn tufts/filaments of the carpet product. Itis further contemplated that the chemicals can be applied via a lickroller. In another aspect, the chemical means can comprise a bead of hotmelt or other similar polymers that can be extruded to form a retainingring around the carpet product. In this aspect, the polymer can be leftin place after installation or removed once the carpet product isinstalled.

In exemplary aspects, the perimeter yarn tufts of the carpet product canbe physically and mechanically connected to inland adjacent yarn tuftsto retain the non-entangled filaments of the perimeter yarn tufts in asubstantially perpendicular (i.e., substantially vertical) orientationrelative to the backing material and a substantially parallel orparallel orientation relative to adjacent fiber bundles (yarn tufts). Inthese aspects, the disclosed methods can reduce the likelihood that yarntufts/fibers will become entrapped in the installation process, therebyimproving the quality and process of installation. In exemplary aspects,the disclosed methods can provide security of the edge yarntufts/filaments for the period of shipment and placement on the floorduring installation.

Although described herein with reference to yarn tufts, it iscontemplated that the disclosed methods for inwardly displacing yarn orfilaments to create entanglement can also be applied to woven flooringproducts.

Optionally, in exemplary aspects, the apparatus for needling (includingthe plate) can be designed and made with reciprocating action of theneedles and to handle carpet products (e.g., carpet tiles) of a fixedsize and thickness. Optionally, all four sides of the carpet product canbe needled simultaneously. Alternatively, the edges of the carpetproduct can be needled at different times (optionally, sequentially aspart of a production line). In exemplary aspects, the plate can be astripper plate, such as an integrated and removable lamella plate whichcan function as a bed plate. In other exemplary aspects, the needles canhave a shank, barbs and/or a blade as are known in the art. In theseexemplary aspects, the barbs can point in the direction of the tip andbe configured to pull filaments on the inward plunge stroke and entanglethe filaments to provide mechanical fastening. On the extraction of theneedle, it is contemplated that the barbs will have no effect on theyarn tufts/filaments and leave the yarn tufts/filaments in the entangledconfiguration. Optionally, such needles can be purchased from FosterNeedle (for example, FNC5240506), Groz-Bechert, or Novo. In otherexemplary aspects, cut yarn tufts/filaments can be added to the edges ofthe tile to create physical connections with adjacent yarntufts/filaments. Optionally, in these aspects, the added yarntufts/filaments can be a low denier short fiber or a low melt fiber web,which can be applied to the edges via a small carded web material orother means known in the art. In one exemplary aspect, the added yarntufts/filaments can be needled into the edges to provide a mechanicalbond as with no added yarn tufts/filaments. Alternatively, heat can beused to activate the low melt material of the adjacent edge yarntufts/filaments and bond the edges together with a chemical/mechanicalbond of the low melt fibers. Optionally, in these exemplary aspects, theweb can be applied from a dedicated card or by application of a thin webor by scattering of fibers.

In still further aspects, disclosed are packaging containers forshipment and storage of the completed carpet products (e.g., tiles). Inthese aspects, the packing containers can have sizes that arecomplementary to the size of the cut carpet product (e.g., have innerdimensions that are precisely the same size as the outer dimensions ofthe carpet product). In these aspects, as the tile is pressed in theshipping and storage box, the face fiber tufts on the edges tufts can beheld upright and retained in the upright position, and this position canbe maintained during the shipment process. At the time of installation,the tiles can be removed from the end of the container that is oppositeto the end by which the carpet product was inserted into the container,thereby ensuring that the carpet product is provided with the uprighttuft position. Optionally, the packaging container can contain a slipresistant band at the top of the container to “comb” the yarntufts/filaments in the proper upright orientation when being pushed intothe box.

EXPERIMENTAL EXAMPLES

The presently described technology and its advantages will be betterunderstood by reference to the following examples. These examples areprovided to describe non-exhaustive embodiments of the presenttechnology. By providing these examples, the scope of the presentlydescribed and claimed technology is not limited in spirit or scope. Itwill be understood by those skilled in the art that the full scope ofthe presently described technology encompasses at least the subjectmatter defined by the claims appending this specification, and anyalterations, modifications, derivatives, combinations, or equivalents ofthose claims. Further, the citations provided herein are herebyincorporated by reference for the cited subject matter.

Example 1: Amount of Fiber Edge Failure

In one experimental example, the amount of fiber edge failure of aconventional carpet product having unsecured edge fibers was determined.To determine the amount of fiber edge failure of the conventional carpetproduct, a baseline number, referred to as A_(frame1) (FIG. 6A) wasobtained by using SIGMASCAN software (Systat Software Inc.) to determinethe percent cover of the exposed area known as A_(frame1) when overlaidwith A_(tile), representing the area of the carpet tile backing.SIGMASCAN used a selective pixel count, on a preset color basis, todetermine the relative percent area, compared to the total pixels in theimage. A carpet tile sample (Sample_(unsecured)) with unsecured edgefibers and the same backing dimensions as A_(tile), was then picturedsimilarly to the baseline measurement, with additional fiberencroachment onto A_(frame2) (FIG. 6B). This encroachment, describedherein as percent edge failure, was measured as the ratio betweenA_(frame2) and A_(frame1), relative to the originally exposedA_(frame1), as shown below:

${\%\mspace{14mu}{Edge}\mspace{14mu}{failure}} = {\left\lbrack {1 - \left( \frac{A_{\;^{{frame}\; 2}}}{A_{\;^{{frame}\; 1}}} \right)} \right\rbrack \times 100}$

In exemplary aspects, it is contemplated that the Percent Edge Failureof the carpet products disclosed herein can range from about 0 to about25 percent and, more preferably, range from about 0 to about 5 percent.

Example 2: Degree of Fiber Edge Failure

In another experimental example, the degree of fiber edge failure of acarpet product 10, as described herein, was compared to the degree offiber edge failure of a conventional carpet product having unsecurededges. FIG. 7A shows a carpet product 10 having a vertical plane 46 thatextends substantially perpendicularly or perpendicularly to a plane 13of the primary backing layer 12 and coincides with (i.e., is alignedwith) an edge of the primary backing layer 12. A measured angle bySIGMASCAN software was used to determine the total angle between theprimary backing layer 12 and the reference plane 42, which is tangent tothe most outer tuft. The edge failure angle was equal to the differencebetween the measured total angle between the primary backing layer 12and the reference plane 42 (Angle_(Sigmascan)) and the 90 degree angleformed between the primary backing layer 12 and the vertical plane 46,as shown below:° Edge failure=Angle_(Sigmascan)−90°

In this example, as shown in FIG. 7A, the degree of Edge Failure(corresponding to selected angle 44) for the carpet product havingentangled edge fibers as disclosed herein was 31.2°. In contrast, asshown in FIG. 7B, the degree of Edge Failure for the carpet producthaving unsecured edges was 80°.

Exemplary Aspects

In view of the described devices, systems, and methods and variationsthereof, herein below are described certain more particularly describedaspects of the invention. These particularly recited aspects should nothowever be interpreted to have any limiting effect on any differentclaims containing different or more general teachings described herein,or that the “particular” aspects are somehow limited in some way otherthan the inherent meanings of the language literally used therein.

Aspect 1: A carpet product comprising: a primary backing layer having atop surface and a plurality of edges; and a plurality of yarn tuftstufted in and extending upwardly from the top surface of the primarybacking layer to form a tufted carpet product, the tufted carpet producthaving an inner portion and a peripheral portion surrounding at least aportion of the inner portion and extending along at least one of theedges of the primary backing layer, wherein the plurality of yarn tuftscomprises a plurality of peripheral yarn tufts positioned within theperipheral portion of the tufted carpet product, wherein the pluralityof peripheral yarn tufts comprises a first plurality of peripheral yarntufts and a second plurality of peripheral yarn tufts, wherein at leasta portion of each peripheral yarn tuft of the first plurality ofperipheral yarn tufts is entangled with one or more of the peripheralyarn tufts of the second plurality of peripheral yarn tufts.

Aspect 2: The carpet product of aspect 1, wherein the carpet product isa broadloom carpet.

Aspect 3: The carpet product of aspect 1, wherein the carpet product isa carpet tile.

Aspect 4: The carpet product of any one of the preceding aspects,wherein the pile height of the tufted yarn tufts varies over the tuftedcarpet.

Aspect 5: The carpet product of any one of the preceding aspects,wherein the peripheral portion of the tufted carpet product completelysurrounds the inner portion of the tufted carpet product.

Aspect 6: The carpet product of aspect 5, wherein the peripheral portionextends inwardly from the edges of the primary backing layer and has awidth that is less than about 30% of the operative width of the tuftedcarpet.

Aspect 7: The carpet product of any one of the preceding aspects,wherein, following entanglement with the second plurality of peripheralyarn tufts, the peripheral yarn tufts of the first plurality ofperipheral yarn tufts have a mechanical stand fastness sufficient toprevent radial displacement of any peripheral yarn of the firstplurality of peripheral yarn tufts beyond a reference plane that ispositioned at a selected angle relative to a vertical plane that issubstantially perpendicular or perpendicular to the primary backinglayer, wherein the selected angle is less than about 40 degrees.

Aspect 8: The carpet product of aspect 7, wherein the selected angle isless than about 30 degrees.

Aspect 9: The carpet product of aspect 7, wherein the selected angle isless than about 20 degrees.

Aspect 10: The carpet product of aspect 7, wherein the selected angle isless than about 10 degrees.

Aspect 11: The carpet product of aspect 7, wherein the selected angle isless than about 5 degrees.

Aspect 12: The carpet product of aspect 7, wherein the selected angle isabout 0 degrees.

Aspect 13: The carpet product of aspect 7, wherein the selected angle isnegative such that at least a portion of the peripheral yarn tuft of thefirst plurality of peripheral yarn tufts is angled inwardly away from anedge of the carpet product.

Aspect 14: The carpet product of any one of the preceding aspects,wherein at least a portion of at least one peripheral yarn tuft of thefirst plurality of peripheral yarn tufts is entangled with one or moreyarn tufts within the inner portion of the tufted carpet product.

Aspect 15: The carpet product of any one of the preceding aspects,wherein each peripheral yarn tuft of the first plurality of peripheralyarn tufts is entangled with at least two other yarn tufts of the tuftedcarpet product.

Aspect 16: The carpet product of any one of the preceding aspects,wherein each peripheral yarn tuft of the first plurality of peripheralyarn tufts comprises at least one filament that has a tip that isdisplaced inwardly by a selected distance when the peripheral yarn tuftof the first plurality of peripheral yarn tufts is entangled with otheryarn tufts, and wherein the selected distance ranges from about 0.1 inchto about 1.0 inch.

Aspect 17: The carpet product of any one of the preceding aspects,wherein the entanglement of peripheral yarn tufts ensures that noperipheral yarn tuft of the first plurality of peripheral yarn tuftsextends radially beyond a reference plane that is positioned at aselected angle relative a vertical plane that is substantiallyperpendicular or perpendicular to the primary backing layer, wherein theselected angle is less than about 40 degrees.

Aspect 18: A carpet product comprising: a primary backing layer having atop surface and a plurality of edges; and a plurality of yarn tuftstufted in and extending upwardly from the top surface of the primarybacking layer to form a tufted carpet product, the tufted carpet producthaving an inner portion and a peripheral portion surrounding at least aportion of the inner portion and extending along at least one of theedges of the primary backing layer, wherein the plurality of yarn tuftscomprises a plurality of peripheral yarn tufts positioned within theperipheral portion of the tufted carpet product, wherein the pluralityof peripheral yarn tufts comprises a plurality of vertical peripheralyarn tufts that are oriented substantially perpendicularly orperpendicularly to the primary backing layer and a plurality of anchoredperipheral yarn tufts, wherein at least a portion of each anchoredperipheral yarn tuft is entangled with one or more of the verticalperipheral yarn tufts, and wherein the entanglement of peripheral yarntufts ensures that no anchored peripheral yarn tuft extends radiallybeyond a reference plane that is positioned at a selected angle relativea vertical plane that is substantially perpendicular or perpendicular tothe primary backing layer, wherein the selected angle is less than about40 degrees.

Aspect 19: The carpet product of aspect 18, wherein the carpet productis a broadloom carpet.

Aspect 20: The carpet product of aspect 18, wherein the carpet productis a carpet tile.

Aspect 21: The carpet product of any one of aspects 18-20, wherein theperipheral portion of the tufted carpet product completely surrounds theinner portion of the tufted carpet product.

Aspect 22: The carpet product of any one of aspects 18-21, wherein theanchored peripheral yarn tufts have a mechanical stand fastnesssufficient to prevent radial displacement of any anchored peripheralyarn tuft beyond the reference plane.

Aspect 23: The carpet product of any one of aspects 18-22, wherein theselected angle is less than about 30 degrees.

Aspect 24: The carpet product of any one of aspects 18-22, wherein theselected angle is less than about 20 degrees.

Aspect 25: The carpet product of any one of aspects 18-22, wherein theselected angle is less than about 10 degrees.

Aspect 26: The carpet product of any one of aspects 18-22, wherein theselected angle is less than about 5 degrees.

Aspect 27: The carpet product of any one of aspects 18-22, wherein theselected angle is about 0 degrees.

Aspect 28: The carpet of product of any one of aspects 18-22, whereinthe selected angle is negative such that at least a portion of theanchored peripheral yarn tuft is angled inwardly away from an edge ofthe carpet product.

Aspect 29: The carpet product of any one of aspects 18-28, wherein atleast a portion of at least one anchored peripheral yarn tuft isentangled with one or more yarn tufts within the inner portion of thetufted carpet product.

Aspect 30: The carpet product of any one of aspects 18-29, wherein eachanchored peripheral yarn tuft is entangled with at least two other yarntufts of the tufted carpet product.

Aspect 31: The carpet product of aspects 18-30, wherein at least onefilament of each anchored peripheral yarn tuft has a tip that isdisplaced inwardly by a selected distance when the anchored peripheralyarn tuft is entangled with other yarn tufts, and wherein the selecteddistance ranges from about 0.1 inch to about 1.0 inch.

Aspect 32: A method comprising: displacing a first plurality ofperipheral yarn tufts of a tufted carpet product in an inward directionto entangle a second plurality of peripheral yarn tufts of the tuftedcarpet product, each of the peripheral yarn tufts being tufted in andextending upwardly from a top surface of a primary backing layer of thetufted carpet product, wherein the entanglement of the yarn tufts of thefirst plurality of peripheral yarn tufts with the yarn tufts of thesecond plurality of peripheral yarn tufts anchors the first plurality ofperipheral yarn tufts in a desired orientation relative to the primarybacking layer.

Aspect 33: The method of aspect 32, wherein the first plurality of yarntufts and the second plurality of yarn tufts are positioned within aperipheral portion of the tufted carpet product, and wherein theperipheral portion of the tufted carpet product surrounds at least aportion of an inner portion of the tufted carpet product.

Aspect 34: The method of aspect 33, wherein the first plurality ofperipheral yarn tufts are displaced using at least one needle that isinserted into the peripheral yarn tufts in the inward direction.

Aspect 35: The method of aspect 34, wherein the at least one needle isinserted into the peripheral yarn tufts at a desired time and speed.

Aspect 36: The method of aspect 34, wherein the at least one needle isinserted through at least one opening in a plate, wherein the plate isoriented substantially perpendicular or perpendicular to the primarybacking layer, and wherein the inward direction is substantiallyparallel or parallel to the primary backing layer.

Aspect 37: The method of aspect 36, wherein the at least one opening ofthe plate comprises a plurality of openings.

Aspect 38: The method of aspect 37, wherein the plurality of openingsare staggered.

Aspect 39: The method of aspect 37, wherein the plurality of openingsare linear.

Aspect 40: The method of aspect 37, wherein each opening of theplurality of openings is spaced from adjacent openings by apredetermined distance ranging from about 1 mm to about 3 cm.

Aspect 41: The method of aspect 35, wherein each needle reciprocates ata rate ranging from 100 strokes per minute to about 2,000 strokes perminute.

Aspect 42: The method of aspect 35, wherein each needle is insertedwithin the peripheral yarn tufts to a location that is a selecteddistance from an edge of the primary backing layer of the tufted carpetproduct, and wherein the selected distance ranges from about 0.1 inch toabout 1 inch.

Aspect 43: The method of any one of aspects 32-42, wherein the carpetproduct is a broadloom carpet.

Aspect 44: The method of any one of aspects 32-42, wherein the carpetproduct is a carpet tile.

Aspect 45: The method of aspect 33, wherein the peripheral portion ofthe tufted carpet product completely surrounds the inner portion of thetufted carpet product.

Aspect 46: The method of aspect 33, wherein the yarn tufts of the firstplurality of peripheral yarn tufts have a mechanical stand fastnesssufficient to prevent radial displacement of any peripheral yarn tuftsof the first plurality of peripheral yarn tufts beyond a reference planethat is positioned at a selected angle relative a vertical planecoinciding with an edge of the primary backing layer, wherein theselected angle is less than about 40 degrees.

Aspect 47: The method of aspect 46, wherein the selected angle is lessthan about 30 degrees.

Aspect 48: The method of aspect 46, wherein the selected angle is lessthan about 20 degrees.

Aspect 49: The method of aspect 46, wherein the selected angle is lessthan about 10 degrees.

Aspect 50: The method of aspect 46, wherein the selected angle is lessthan about 5 degrees.

Aspect 51: The method of aspect 46, wherein the selected angle is about0 degrees.

Aspect 52: The method of aspect 46, wherein the selected angle isnegative such that at least a portion of the peripheral yarn tuft of thefirst plurality of peripheral yarn tufts is angled inwardly away from anedge of the carpet product.

Aspect 53: The method of aspect 33, wherein at least a portion of atleast one peripheral yarn tuft of the first plurality of peripheral yarntufts is entangled with one or more yarn tufts within the inner portionof the tufted carpet product.

Aspect 54: The method of aspect 33, wherein each peripheral yarn tuft ofthe first plurality of peripheral yarn tufts is entangled with at leasttwo other yarn tufts of the tufted carpet product.

Aspect 55: A carpet product comprising: a primary backing layer having atop surface; and a plurality of yarn tufts tufted in and extendingupwardly from the top surface of the primary backing layer to form atufted carpet product, wherein the plurality of yarn tufts comprises aplurality of substantially vertical yarn tufts that are orientedperpendicularly or substantially perpendicularly to the primary backinglayer and a plurality of anchored yarn tufts, wherein at least a portionof each anchored yarn tuft is entangled with one or more of thesubstantially vertical yarn tufts.

All publications and patent applications mentioned in the specificationare indicative of the level of those skilled in the art to which thisinvention pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated to be incorporated by reference.

Although the foregoing invention has been described in some detail byway of illustration and example for purposes of clarity ofunderstanding, certain changes and modifications may be practiced withinthe scope of the appended claims.

What is claimed is:
 1. A method comprising: displacing a first plurality of peripheral yarn tufts of a tufted carpet product in an inward direction away from a periphery of the tufted carpet product to entangle, without heat fusion, a second plurality of peripheral yarn tufts of the tufted carpet product that are positioned inwardly of the first plurality of peripheral yarn tufts, each of the first and second plurality of peripheral yarn tufts being tufted in and extending upwardly from a top surface of a primary backing layer of the tufted carpet product, wherein entanglement of the yarn tufts of the first plurality of peripheral yarn tufts with the second plurality of peripheral yarn tufts anchors the first plurality of peripheral yarn tufts to the second plurality of peripheral yarn tufts, wherein the yarn tufts of the first plurality of peripheral yarn tufts and the second plurality of peripheral yarn tufts are mechanically secured to one another without being chemically adhered to one another, and wherein displacing the first plurality of peripheral yarn tufts of the tufted carpet product in the inward direction to entangle the second plurality of peripheral yarn tufts of the tufted carpet product comprises reciprocally moving a needle into the first plurality of peripheral yarn tufts in the inward direction and outwardly from the first plurality of peripheral yarn tufts in an opposed outward direction.
 2. The method of claim 1, wherein the first plurality of peripheral yarn tufts and the second plurality of peripheral yarn tufts are positioned within a peripheral portion of the tufted carpet product, and wherein the peripheral portion of the tufted carpet product surrounds at least a portion of an inner portion of the tufted carpet product.
 3. The method of claim 2, wherein the peripheral portion of the tufted carpet product surrounds an entirety of the inner portion of the tufted carpet product.
 4. The method of claim 1, wherein the tufted carpet product has an operative width between a first edge and a second edge, wherein the entanglement of the yarn tufts of the first plurality of peripheral yarn tufts with the yarn tufts of the second plurality of peripheral yarn tufts extends inwardly from each of the first edge and the second edge by less than 30% of the operative width.
 5. The method of claim 1, wherein the tufted carpet product is a broadloom carpet.
 6. The method of claim 1, wherein the tufted carpet product is a carpet tile.
 7. The method of claim 2, wherein the entanglement of the yarn tufts of the first plurality of peripheral yarn tufts with the yarn tufts of the second plurality of peripheral yarn tufts causes the peripheral yarn tufts of the first plurality of peripheral yarn tufts to have a mechanical stand fastness sufficient to prevent radial displacement of any peripheral yarn tuft of the first plurality of peripheral yarn tufts beyond a reference plane that is positioned at a selected angle relative a vertical plane that is perpendicular to the primary backing layer, wherein the selected angle is less than 40 degrees.
 8. The method of claim 7, wherein the selected angle is less than 30 degrees.
 9. The method of claim 7, wherein the selected angle is less than 20 degrees.
 10. The method of claim 7, wherein the selected angle is less than 10 degrees.
 11. The method of claim 7, wherein the selected angle is negative such that at least a portion of the peripheral yarn tuft of the first plurality of peripheral yarn tufts is angled inwardly away from an edge of the carpet product.
 12. The method of claim 2, wherein displacing the first plurality of peripheral yarn tufts of the tufted carpet product in the inward direction to entangle the second plurality of peripheral yarn tufts of the tufted carpet product comprises entangling at least a portion of at least one peripheral yarn tuft of the first plurality of peripheral yarn tufts with one or more yarn tufts within the inner portion of the tufted carpet product.
 13. The method of claim 1, wherein displacing the first plurality of peripheral yarn tufts of the tufted carpet product in the inward direction to entangle the second plurality of peripheral yarn tufts of the tufted carpet product comprises entangling at least one yarn tuft of the first plurality of yarn tufts with at least two other yarn tufts of the tufted carpet product.
 14. The method of claim 1, wherein each peripheral yarn tuft of the first plurality of peripheral yarn tufts comprises at least one filament having a tip, wherein displacing the first plurality of peripheral yarn tufts of the tufted carpet product in the inward direction to entangle the second plurality of peripheral yarn tufts of the tufted carpet product comprises displacing the tip of each yarn tuft of the first plurality of peripheral yarn tufts by a select distance, wherein the select distance ranges from about 0.1 inch to about 1.0 inch.
 15. A method comprising: displacing a first plurality of peripheral yarn tufts of a tufted carpet product in an inward direction away from a periphery of the tufted carpet product to entangle a second plurality of peripheral yarn tufts of the tufted carpet product that are positioned inwardly of the first plurality of peripheral yarn tufts, each of the first and second plurality of peripheral yarn tufts being tufted in and extending upwardly from a top surface of a primary backing layer of the tufted carpet product, wherein entanglement of the yarn tufts of the first plurality of peripheral yarn tufts with the second plurality of peripheral yarn tufts anchors the first plurality of peripheral yarn tufts to the second plurality of peripheral yarn tufts, wherein the first plurality of peripheral yarn tufts are displaced using at least one needle that is inserted into the first peripheral yarn tufts in the inward direction.
 16. The method of claim 15, wherein the at least one needle comprises a plurality of needles.
 17. A method comprising: displacing a first plurality of peripheral yarn tufts of a tufted carpet product in an inward direction so that each yarn tuft of the first plurality of yarn tufts entangles, without heat fusion, at least one other tuft of the tufted carpet product in order to anchor the first plurality of peripheral yarn tufts in a desired orientation relative to the primary backing layer, wherein each yarn tuft of the tufted carpet product is tufted in and extends upwardly from a top surface of a primary backing layer of the tufted carpet product, wherein the yarn tufts of the first plurality of peripheral yarn tufts and the second plurality of peripheral yarn tufts are mechanically secured to one another without being chemically adhered to one another, and wherein displacing the first plurality of peripheral yarn tufts of the tufted carpet product in the inward direction to entangle the second plurality of peripheral yarn tufts of the tufted carpet product comprises moving a needle in the inward direction across an edge of the primary backing layer. 